AS9102 First Article Inspection (FAI) Guide for CNC Machined Parts

What AS9102 Is and When It Is Required

AS9102 (currently Revision C, released August 2023) defines the minimum requirements for documenting that a first production article complies with the engineering drawing, purchase order, and applicable specifications. It applies to parts and assemblies for aerospace, defense, and space programs governed by AS9100 quality management systems. Most prime contractors flow AS9102 down to subtier suppliers contractually — meaning that if a prime requests a first article on your part, an AS9102-conformant FAI package is the deliverable.

FAI is required when (1) a part is produced for the first time, (2) the design, tooling, process, or supplier changes, (3) a lapse of two or more years has occurred since the last production run, or (4) the customer specifies it on the purchase order. Common triggers include a revision change to the drawing, a material substitution, a change in the manufacturing facility, or a change in the inspection method.

Rev B vs Rev C key differences: Revision C clarifies the treatment of digital product definitions (model-based definition, or MBD), expands guidance on partial FAIs (PFAI), and tightens the rules around traceability of special processes. Rev C also formalizes the treatment of additive manufacturing characteristics. Olympus Machining produces FAI packages to the customer-specified revision — most current programs require Rev C.

Form 1 — Part Number Accountability

Form 1 establishes the identity of the part being inspected. It captures the part number, part name, drawing number and revision, serial or lot number, manufacturing process record (router, traveler, or work order number), and whether the FAI is a full FAI or partial FAI (PFAI). For assemblies, Form 1 also lists every sub-component part number and indicates whether each sub-component has its own FAI.

Olympus Machining populates Form 1 from the customer purchase order and our internal job traveler. Because we operate under documented procedures with traveler-controlled revision tracking, the Form 1 entries are pulled directly from the work order rather than transcribed by hand — eliminating the most common source of Form 1 rejections (mismatch between part revision on the form and the revision actually built).

See the related guide: Full FAI vs Partial FAI — when each is required.

Form 2 — Product Accountability for Materials and Special Processes

Form 2 documents the raw material certifications and any special processes (heat treat, plating, anodizing, passivation, NDT, welding) applied to the part. Each line item captures the specification (e.g., AMS-QQ-A-250/11 for 6061-T6 plate, or AMS 2700 for stainless passivation), the actual certification number, the name of the supplier or processor, and the date of certification.

Olympus Machining maintains material certifications and process certifications in a controlled job folder for every order. For special processes routed to outside vendors — anodizing, plating, heat treat, NDT — we require Nadcap-accredited (where applicable) or customer-approved suppliers, and the certification copies are bound into the FAI package alongside our internally generated documentation.

For ITAR-controlled parts, Form 2 also documents the chain of custody from raw material receipt through finished part — supporting the traceability requirements of FAR 52.204-21 and our CMMC Level 1 alignment.

Form 3 — Characteristic Accountability

Form 3 is the dimensional report. Every drawing characteristic — dimension, tolerance, GD&T callout, surface finish, material requirement, and note — is assigned a balloon number on a balloon-annotated drawing. Form 3 then lists, for each balloon: the requirement (nominal and tolerance), the actual measured value, the inspection method (CMM, micrometer, gage pin, vision system), and the accept/reject result.

Olympus Machining produces balloon drawings using High QA and equivalent inspection planning software. The balloon drawing becomes the master reference for Form 3 entries, ensuring that no characteristic is missed and that balloon numbering is consistent between the drawing and the form.

For a deeper walkthrough of the balloon-numbering process, see How Balloon Drawings Work for AS9102 Form 3.

Olympus Machining FAI Workflow

1. 1. Balloon the drawing

   Every callout on the customer print is assigned a unique balloon number using High QA. The balloon drawing is reviewed against the engineering drawing for completeness before any chips are cut.

2. 2. Build the CMM program

   Inspection programs are written for the Haas HMM 430 (3-axis CMM) and the Chien Wei CWB-450-CNC (CNC CMM with rotary table) to capture every dimensional characteristic on the balloon drawing.

3. 3. Machine the first article

   The part is machined on our 3-, 4-, or 5-axis CNC mills or live-tooling lathes using the documented setup that will be used for production. The first piece off the setup is the first article.

4. 4. Run CMM and supplemental inspection

   The CMM program is executed; non-CMM characteristics (threads, surface finish, visual notes) are inspected with appropriate hand tools, gages, and visual references.

5. 5. Populate Form 1, Form 2, Form 3

   Form 1 is pulled from the traveler; Form 2 from the controlled certification folder; Form 3 from the CMM output and supplemental inspection records.

6. 6. Internal review and customer delivery

   The FAI package is reviewed by our quality lead before being released. The customer receives a PDF package — and, for ITAR programs, the package is delivered through controlled channels per the customer's program security requirements.

Common FAI Rejection Reasons (and How We Prevent Them)

AS9102 Form Templates

Blank AS9102 Rev C Form 1, Form 2, and Form 3 templates are published by SAE International. Customers and engineering teams should download the official templates directly from SAE to ensure they are using the current revision:

Olympus Machining produces FAI packages on the official SAE Rev C forms (or the customer-specified revision when different). Customers do not need to supply blank templates — we provide the completed package.

Request FAI on Your Next Order

Submit your drawing along with a note that you require an AS9102 first article inspection. We will quote the FAI as a separate line item with a clear scope.

Related AS9102 Resources

• • Full FAI vs Partial FAI: When You Need Each
• • How Balloon Drawings Work for AS9102 Form 3
• • CMM Inspection Services for Aerospace Parts (Haas HMM 430)
• • Quality Assurance and Inspection Capabilities
• • CMMC Level 1 Compliance for DoD CNC Suppliers